The Green Revolution Scaling CO₂-negative Pallet Production through Industrial Automation
Challenge
TGR had proven that CO₂-negative pallets could outperform traditional alternatives. The next step was to industrialize production and create a manufacturing process that could scale efficiently while maintaining safety, quality and operational reliability.
Solution
Comate transformed the production concept into an integrated manufacturing system by connecting conveyors, mixers, presses and robotic workstations through a unified automation and safety architecture. This created the foundation for industrial-scale production of biobased transport pallets.
What impressed us most about working with Comate was their service, clear communication, and commitment to going the extra mile.
AMBITION Bringing sustainable pallet production to industrial scale
The Green Revolution (TGR Pallets) developed a breakthrough transport pallet made from locally grown Miscanthus, delivering a CO₂-negative alternative to traditional pallets while improving logistics efficiency through lightweight and nestable design. The solution had already proven its value in real-world logistics environments, including extensive testing with DHL.
The next challenge was clear: how do you scale production of an innovative product while maintaining consistency, safety and operational efficiency?
INTEGRATION Connecting machines, controls and safety into one production system
Producing a novel biobased pallet requires much more than a mould and a press.
Multiple suppliers, machines, conveyors, mixers, presses and robotic workstations had to operate as one integrated manufacturing system. To support future growth, the entire process required centralized control, machine safety engineering and robust automation.
APPROACH Translating a production vision into a fully automated manufacturing line
Comate acted as the system integration and automation partner, translating TGR's production vision into an operational industrial setup.
Our multidisciplinary team developed:
- Production line architecture
- Automation strategy
- Functional safety concept
- PLC software architecture
- Machine integration
- Robot interfacing
- Human-machine interaction
- Verification and testing framework
This transformed a collection of standalone production assets into a coordinated manufacturing line.
RESULT A scalable foundation for CO₂-negative logistics
The project lays the foundation for industrial-scale manufacturing of TGR's innovative pallets.
By combining sustainable material innovation with advanced automation, TGR is creating the production capabilities needed to support broader adoption of CO₂-negative logistics solutions across Europe.
From concept to industrial-scale production: if you're facing a similar scaling challenge, let's talk about how Comate can help.
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